Spacing means for reflex pin block

ABSTRACT

Spacers or wedges are disclosed for use in combination with mold elements such as lens and/or reflex reflector pins in a pin block or matrix assembly. Such assemblies are used in the manufacture of molds for producing, for example, front and/or rear light units for motor vehicles. The wedges or spacers are selectively located between rows or banks of reflex or optic pins to provide required orientation to selected groups of the pins so that the necessary reflectivity of the finished product is provided in the curved portion thereof.

FIELD OF THE INVENTION

This invention relates to mold matrix assemblies used in the manufactureof reflex reflector and lens units such as, for example, front and rearlight units on automobiles. In particular, the invention is directed tospacing means for use in such matrix assemblies and the combination ofthe spacing means with mold elements in a matrix.

BACKGROUND OF THE INVENTION

A reflective mold matrix consists of a plurality of mold pins such asoptic pins or reflex pins that are assembled into a specificconfiguration. The matrix is used to produce an electroform block, byelectroplating, and this block is then used in the manufacture of a moldwhich receives thermoplastic mold material, under pressure, for makingoptic and reflective devices, for example automobile light assemblies.The reflective prisms in a light assembly are the result of reflector orreflex mold pins used to reflect light back to a source directed at thelight assembly and the optic elements therein may be used, for example,as directional signalling running and stop lights.

Some years ago, light assemblies on vehicles were generally flat, orlocated on flat areas of the vehicles, with reflective portions of thelight assemblies often being incorporated in the bodywork of thevehicle. In many examples, the generally planar outer surfaces of thereflectors of the light assemblies were perpendicular to thelongitudinal axis of the vehicle, or nearly so. However, in recentyears, surfaces of vehicle bodies have been rounded off to provide moredramatic contours in an attempt to lower wind resistance and reducesurface friction and drag.

Accordingly, aerodynamics is playing an increasing role in the designand overall configuration of motor vehicles and this has presentedchallenges in the manufacture of light assemblies, for example front andrear light assemblies, in that those products must not only conform toor blend with the contour of the vehicle bodywork but still provide thereflectivity and optical standards required by law.

It is desirable therefore in the manufacture of a reflective mold matrixto find some way of orienting the mold elements so that the necessaryreflectivity of the finished product is not lost in the curved portionthereof while matching the contour of the vehicle body.

An example of one attempt of meeting the requirement is shown in U.S.Pat. No. 4,733,946 of Mar. 29, 1988 to Cossetti. In this patent, reflexpins are machined such that their side surfaces are tapered towards theface of the matrix so that when the elements are grouped in a matrix,the tapered pins will provide the necessary curvature. However, whilethis may be effective, it is an expensive and time consuming way ofdealing with the matter.

SUMMARY OF THE INVENTION

The present invention addresses the problem referred to above byproviding spacers or wedges for use in combination with mold elementssuch as optic or reflex reflector pins, in the pin block or matrixassembly. The spacers or wedges are selectively located between rows orbanks of mold elements in the matrix to provide the required orientationto the optic reflex pins. The result of this is that the necessaryreflective surfaces from the prisms will return the required amount ofreflected light towards a source even when the surface of the product ison a contoured portion of a light assembly on a vehicle.

According to one broad aspect, the invention relates to a wedge-shapedspacer for use in combination with mold elements in a matrix assembly,the spacer being selectively located between rows or banks of the moldelements to provide orientation to the elements on one side of thespacer with respect to those elements on the other side thereof therebyto compensate for axial changes in the orientation of the mold elementsresulting from curvature of the matrix. The spacer comprises anelongated body having flat parallel side edges and converging facestapering towards one another from a major edge to a minor edge. One ofthe faces has a surface profile to fit the profile of juxtaposedelements in the matrix assembly.

According to a further broad aspect, the invention relates to a moldelement matrix assembly for use in manufacturing a mold for producing acontoured, vehicle light unit. The assembly comprises a plurality moldelements in the form of elongated optic and/or reflex pins withoperative ends, the pins being secured together in a block to provide acontoured matrix surface. At least one wedge-shaped spacer having amajor end and a minor end, is inserted in the assembly, the spacerhaving a width equal to the thickness of said matrix and being locatedwith its minor end adjacent the matrix surface and between banks of themold elements whereby the longitudinal axis of the mold elements on oneside of the spacer are disposed at an angle relative to the elements onthe other side of the spacer.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is illustrated, by way of example, in the accompanyingdrawings in which:

FIG. 1 is an elevation view of an operative face of a matrix assemblyaccording to the invention;

FIG. 2 is a sectional view taken along the line 2--2 of FIG. 1;

FIG. 3 is a plan view of a wedge-shaped spacer of the type shown in FIG.1;

FIG. 4 is a side view of the spacer shown in FIG. 3;

FIG. 5 is a sectional view taken along the line 5--5 of FIG. 4 andlooking toward the minor end of the spacer shown in FIG. 4;

FIG. 6 is a perspective view of the spacer shown in FIG. 3;

FIG. 7 is a fragmentary, sectional plan view of a pair of mold elementswith a spacer therebetween;

FIG. 8 is a fragmentary end view of one form of a spacer according tothe invention;

FIG. 9 is a plan view of a group of rectangular reflex pins;

FIG. 10 is a schematic face end view of the pins in FIG. 9; and

FIG. 11 is a plan view of a further embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1 and 2, a mold element matrix assembly 10 consistsof a pair of groups 12 of elongated pins or mold elements 14 suitablysecured together and held in a carrier 16 by cap screws 18 or the like.In the illustration of FIG. 1, two groups of mold elements, one in theupper part of the carrier and one in the lower part of the carrier areseparated by a relatively thick intermediate member 20.

As shown in FIG. 2, the matrix surface 22 displays a concave contour,the degree of curvature thereof increasing towards the right hand sideof FIG. 2. The pins 14 in group 12 are separated from pins 24 and 26 bytwo wedge-shaped spacers 28 and 30 respectively. Typically, spacers 28and 30 would be of the configuration shown in FIGS. 3-6 inclusive. FIG.2 shows that wedge-shaped spacer 28 serves to offset the longitudinalaxes of the pins 24 by about 3° with respect to the longitudinal axes ofpins 14 in group 12. Further, wedge-shaped spacer 30 adds a furtheroffset of approximately 6° between mold pins 24 on one side thereof andmold pins 26 on the other side thereof.

As seen in FIGS. 3-6, the wedge-shaped spacer 28 has an elongated body32 with flat, parallel side edges 34, 36 and converging faces 38, 40that taper towards one another from a major edge 42 to a minor edge 44.

It will be appreciated that the design of the matrix will dictate theconfiguration of the pins or elements 14, 24, 26 being used. However, asan example, pins or elements 14 in group 12, as shown in FIG. 1, have ahexagonal cross-section while the pins in group 24, for example, may beof rectangular cross-section. In such an arrangement, the wedge-shapedspacer 28 would have one of its faces, in this case, face 38, beingprovided with a surface profile 46 to compliment the profile of thejuxtaposed elements 14 adjacent to it in the matrix assembly. As thepins or elements 24 on the other side of the wedge-shaped spacer 28would be of rectangular configuration, they would fully engage the flat,planar face 40 of the spacer 28.

FIG. 8 is an enlarged view of a portion of the minor end 44 of a spacer28 showing the profile 46 to compliment the arrangement of the hexagonalcross-section pins.

FIG. 7 shows the relationship between the minor end 44 of a spacer 28located between two banks of reflex pins 14. The terminal, minor end 44of the spacer is located inwardly of the shoulder portions of the pins14 so that the shoulders engage one another as illustrated.

FIGS. 9, 10 and 11 illustrate embodiments where selected mold elementsare oriented with respect to adjacent elements by means of individualspacers. Generally, when spacers are used between rectangular moldelements, both reflex and optic individual spacers are used and whichhave a width equal to that of one mold element. As shown in FIGS. 9 and10, individual spacers 128 having a width "W" can be located alongstraight lines, such as 129, across the width of the matrix or staggered(not shown) if this works better with the profile of the lens.

The individual spacers are aligned to each mold element and, as shown inFIG. 11 spacers 228 are sometimes secured to their associated pins 214by suitable fastening means such as two small pins 230.

It will be appreciated that as many wedge-shaped spacers that arenecessary can be used in a matrix to meet the requirements oforientation of the pins therein.

While the invention has been described in connection with a specificembodiment thereof and in a specific use, various modifications thereofwill occur to those skilled in the art without departing from the spiritand scope of the invention as set forth in the appended claims.

The terms and expressions which have been employed in this specificationare used as terms of description and not of limitations, and there is nointention in the use of such terms and expressions to exclude anyequivalents of the features shown and described or portions thereof, butit is recognized that various modifications are possible within thescope of the invention claims.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows:
 1. A wedge-shaped spacerfor use in combination with mold elements in a matrix assembly, saidspacer being selectively located between rows or banks of said moldelements to provide selective orientation to said elements on one sideof said spacer with respect to those elements on the other side thereofthereby to compensate for axial changes of said mold elements resultingfrom curvature of said matrix;said spacer comprising an elongated bodyhaving flat parallel side edges and converging faces tapering towardsone another from a major edge to a minor edge; at least one of saidfaces having a surface profile to complement the profile of juxtaposedelements in said matrix assembly.
 2. A mold element matrix assembly foruse in manufacturing a mold for producing a contoured lens or reflectorunit, said assembly comprising a plurality of elongated pins or elementswith operative ends, and said elements being secured together in a blockto provide a contoured matrix surface; and at least one wedge-shapedspacer in said assembly and having a major end and a minor end, saidspacer having a width equal to the thickness of said matrix and beinglocated in said assembly with its minor end adjacent the matrix surfaceand between banks of said pins or elements whereby the longitudinal axesof the pins or elements on one side of the spacer are disposed at anangle relative to the pins or elements on the other side of the spacer.3. A matrix assembly according to claim 2 wherein the minor end of saidspacer sits inwardly of the matrix surface.
 4. A matrix assemblyaccording to claim 2 wherein said spacer has a profile on one of itsfaces to complement the profile of juxtaposed pins or elements in saidassembly.
 5. A wedge-shaped spacer for use in combination with moldelements in a matrix assembly, said spacer being selectively locatedbetween rows or banks of said mold elements to provide selectiveorientation to said elements on one side of said spacer with respect tothose elements on the other side thereof thereby to compensate for axialchanges of said mold elements resulting from curvature of saidmatrix;said spacer comprising an elongated body having flat parallelside edges and flat converging faces tapering towards one another from amajor edge to a minor edge; said mold elements in said matrix assemblyon either side of said spacer being rectangular in cross-section, saidspacer being of the same width as the adjacent mold elements.
 6. A moldelement matrix assembly for use in manufacturing a mold for producing acontoured lens or reflector unit, said assembly comprising a pluralityof elongated pins or elements with operative ends, and said elementsbeing secured together in a block to provide a contoured matrix surface;and at least one wedge-shaped spacer in said assembly and having a majorend and a minor end, said spacer having a width equal to the thicknessof adjacent elements in said matrix and being located in said assemblywith its minor end adjacent the matrix surface and between banks of saidpins or elements whereby the longitudinal axes of the pins or elementson one side of the spacer are disposed at an angle relative to the pinsor elements on the other side of the spacer;the mold pins or elements oneither side of each spacer being rectangular in cross-section and anindividual spacer, of the same width of said elements, being associatedwith a single mold pin or element on either side thereof.
 7. A moldelement according to claim 6 wherein the individual spacers aligned toeach mold pin or element are mechanically secured thereto.